Ceiling mold form



July 9, 1940- P. cARlLLl CEILING MOLD FORM Fild Oct. 15, 19:57 5 sheets-sheet 1 .r Yum.

July 9 1940- P. CARILLI l 2,206,939

CEILING MOLD FORM Filed Oct. 13. 1957 5 Sheets-Sheet 2 h3: I gi/YAM lJuly 9, 1940. P, CARILL, 2,206,939

CEILING MOLD FORM Filed oct. 15,1937 5 sheets-sheet s July 9, 1940. R CARILL. 2,206,939

, CEILING MOLD FORM Filed Oct. 13. 19257 5 Sheets-Sheet 5 IVD/@nlm Patented July 9, 1940 UITEDsTATEs rATENT g orme CEILING MOLD FORM Pasquale Carilli, .Mi1ton, Mass. Application October 13, 1937,v Serial No. 168,697

5 claims.' (0125-131)` My invention relates to ceiling mold forms for use in molding poured concrete ceilings such as are made With two sets of parallel ribs or beams disposed at right angles to each other.

The inventionhas for its object to provide an improved molding form for use in constructing ceilings of the type described and illustrated in my U. S. PatentNo. 2,093,401 dated kSepteimber 21, 1937, and it is also an ob-jectof the invention to improve the appearance of ceilings of this type.

Accordingly I have provided the improvements in ceiling mold forms set forth in the following description, the several'novel features; of the invention being separately pointed out and defined in the claims at the close theeof.

In the accompanying drawings:

Figure 1 is a vertical sectional viewof a portion of a ceiling moldv form structure constructed in accordance with the present* invention.

Figure 2 is a vertical sectional view of a ceiling produced by use of the mold form structure shown in Fig. 1. y

` Figure 3 shows a portion-of the structure illustrated in Fig. 1 enlarged to about full size.

Figure 4 is` a perspective View of one of the chairs hereinafter referred to. v n

Figure 4A is a top plan View of the base section of one of the tile units hereinafter referredto.`

Figure `5 is a top plan view'oi' the` mold form apparatus shown in Fig. ibut with the reinforcement supporting chairs removed.

Figure 6 Shows the ceiling that is produced through the use of the apparatus 'shown in Fig.`1.

Figure 7 illustrates an alternative construction embodying certain features of the invention.

Figures 8 and 9` illustrate the use of parts of my improved mold form in producing a hung ceiling. l

Figure 10 is a vertical sectionalview illustrating another form of ceiling mold `for1n` constructed in accordance with this invention.

Figure 11 is a top plan View of the ceiling mold form shown in Fig. 10. v

Figures 12 and 13 show the twotypes of groovef forming and tile-spacing units constituting parts of the mold form illustrated in Figs. 1 0 and l1.

In constructing beamed concrete ceilings, or combined ceilings and iioors, it lhas been common practice to erect a temporary wooden structure on which was vassembled a ceiling mol'd `form made up of a multiplicity of tiles or mold units on to and around which the concrete was poured, said tiles or units being disposed in two sets of separated rows at right anglesto each other so as to pro-Vide the ceiling with two sets of'. spaced apart concrete beams disposed at right angles to each other. A ceiling mold form of the type referred to is shown and described in my U. S. patent referred to above and as in said patented construction the present invention contemplatesV 5 a mold form which is removed in whole or in part after the ceiling has been produced.

The ceiling mold form illustrated in` Figs. 1 to 7, inclusive, comprises a plurality of mold units or tiles each of which comprisestwoseparable 10 sections includinga rectangular sheet metal base section l0 and a hollow upper section which may be a sheet metal dome or cup-shaped element as shown at I i in Figs. 1 and 5, or which may be as shown in Fig. 7, consist of one or more blocks 15 Ila or IIb made from cinder, slag or equivalent material. l

The sheet metal base section i0 is pressed or molded so as to provide the same with a fiat elevated, and preferably rectangular, horizontal top 20 wall I3, Figs.` 1 and 4A, bordered by four downwardly and outwardly sloping side walls I4, and with-an outwardly extending horizontal marginal ange I5 at the basev of eachl side wall I4.

'The topV wall I3 of each base section Iii `is made 25 with a plurality of upstanding lugsl3a, Figs. 1, 1A and 5, disposed adjacent to, but spaced inwardly al short distance away from, the four Ysides ofthe top wall so as to closely surround Eis. 7.

These lugs may conveniently be provided by striking up portions of the top wall i3 as described inA said patent. 35

Atv each corner thereof the flange I5 is beveled as at I6 atan angle, in the illustrated example, of forty-ivedegrees ,relatively to the side walls I4 lso that the ange I5 of each-base section is, as shown, octagonal lat its outer edge or, in other words, polygonal. The purpose of this will appear later.

The upper section I Io-f Figs. 1 to 6 is constructed and co-operates with the base section I0, as in my above noted patent.' This is true also of the 45 l'upper sections Ila and IIbl of Fig. '7.

-in Figs. 10 to 13, inclusive, they are shown at 31 55v and 38 and alternate with the one-piece main mold units Ilc thereof.

The flange I5 of each base section I0 is formed upon its top side with four ribs 39, Figs. 3 and 4A, each of which is parallel with and opposite one of the side walls I4 of the base section, and these ribs are provided to occupy longitudinal grooves twoof which are provided upon the bottom side of each intermediate mold element 35 and 36, one near each side thereof. Thus each base section I6 is separably connected with and definitely spaced apart from neighboring base selections by those intermediate elements with which its flange I5 is interlocked as described. v The longitudinal grooves provided upon the bottom sides of mold elements 35 and 36 are formed by bending the sheet metal blanks from which the elements 35 and 36 are made and the production of said grooves in this manner provides a pair of longitudinal ribs 41, Fig. 3, upon the top side of each intermediate element which form ornamental grooves 4I in the iinished ceiling 26, as shown in. Figs. 2 and 6. As shown in Fig. 5, the opposite ends of the ribs 41 of each element 35 register with the ends of the ribs 41 of abutting elements 35 with the result that each recess or cavity of the nished ceiling is surrounded by a continuous rectangular groove as shown in Fig. 6, thus producing a desirable decorative effect. Thus the intermediate members or mold elements 35 and 36 may also have the important function of embellishing the exposed surfaces of the beams 26a, Fig. 2, of the nished ceiling.

In the preferred form of my invention means is provided for producing the ceiling with an ornamental border 42 disposed between the group of cavities 43 produced by the mold units Ill-I I and the walls 48 of the room, Figs. 2 and 6, and to this I provide a set of border forming mold units for each side of the rectangular group of mold units III-II, said set consisting of an inner series of molded sheet metal sections or strips 36 arranged end to end and an outer series of molded sheet metal sections or strips 31, the endmost `sections of each series having beveled ends abutting the proximate ends oi the endmost sections of adjacent sets to provide closed miter joints at the corners of the room as shown at 46 in Fig. 5.

In producing a ceiling by means of the above described mold units, a wooden form-supporting structure 43, Fig. '1, is erected upon the floor below the proposed ceiling, and this structure may include a plurality of horizontal stringers 22 which extend across the room and in most part are uniformly spaced apart a distance equal to the distance between the longitudinal medial linee of two relatively parallel mold units 35 or 36 as will be clear from Fig. '1 so that two oppositely disposed flanges of each base section I rest thereon, the mold strips 35 being laid on top of the flanges I at all four sides of each of the innermost mold units III-II, as shown in 5, and the mold strips 36 being laid on the flanges I5 between each outermost or marginal unit I-II and its two neighbors in that group of units.

Both ends of each mold strip 35 are pointedly beveled sothat the abutting ends of each group of proximate strips 35 will match up and provide closed nnter joints as at 50, Fig. 5, while the inner ends only of the strips 36 are pointedly beveled so as to match up with the beveled ends of the two strips 35 with which it abuts so as to provide closed miter joints as shown at 5I. The outer ends of the mold strips 36 are squared oil? as shown so as to t against the inner edges of the sections 38.

The inner marginal portions of the sections 38 are formed upon their top sides with alined longitudinal ribs 52, Figs. 1, 2 and 5, against which the outer ends of ribs 41 of the mold strips 36 abut. Thus the ornamental grooves 4I, Fig. 6, which are formed in the finished ceiling by the ribs 41, merge into or join the groove 53 produced by the ribs 52 of the border forming elements 38.

It will now be clear that the purpose in bevel- .ing the corners of the flange I5 of each base section IIJ as at I6, Fig. 4A, is to allow the mold strips 35 and 36 to intermesh or interlock properly therewith.

The abutting beveled ends of the strips 35 and 36 are shaped to provide small holes 54, Fig. 5, to receive nails by means of which the strips are secured in vposition upon the stringers 22, while the outer ends of the strips 36 are formed with notches for the same purpose. y

After themold form has been assembled upon the wooden supporting structure a number of reinforcement-supporting chairs 24 are placed in position, across the lower portions of a plurality of beam-forming channels 25, Fig. 1, now existing between adjacent units I5-I I, one end of each chair resting upon the outer marginal portion of the b-ase section I0 of one unit and its other end resting upon the outer marginal portion of the opposite base section. These chairs support reinforcing bars 21.

The concrete is now poured or otherwise deposited upon the mold form and when set the temporary wooden supporting structure and all of the mold units are removed leaving a rein,

forced cellular beamed ceiling structure.

The removal of each unit III-II leaves a cavity or pocket 43 which is countersunk at its outer lower end to receive a panel of acoustical board, mill board or lother suitable material.

When the base sections I0 of the main units shown in Fig. 7 are removed the upper sections IIa and IIb remain permanently incorporated within the ceiling and may be covered and hidden from view by panels 29 such as shown in Figs. 2 and 6.

As shown in Figs. 3 and 4 each chair 24 may be made at its opposite ends with apertures 32 for the reception of split self-clinching nails 3| adapted to occupy two holes 33 provided in the top walls of the two base sections by which the chair is supported. The panels 29 are driven on to the nails 3I which positively hold the sam-e in position within the countersinks.

Other reinforcement-supporting chairs may be associated with the outermost units IIi-II of the assembled mold form as shown at 24a, Fig. 7.

Herein I have provided for use of portions of the above described mold-apparatus in constructing a hung paneled ceiling, viz., a comparatively thin ceiling which is suspended from a roof or other overhead support. To this end I assemble a group of base sections Ill and mold elements 35, Figs. 8 and 9, upon the temporary wooden supporting structure 49, dispensing with the upper sections II of the main mold units, and employ a number of reinforcement-supporting chairs 24h each of which is constructed with an upstanding extension 55 whose lower portion 56 is welded or otherwise securely fastened thereto.

A quantity of a well known product that is employed in the production of hung ceilings is then deposited on the mold form which expands into a light porous body 51 as it sets and hardens th-ereby providing a thin, light ceiling.

The extensions 55 are formed with holes 58 for the reception of bolts by means of which they are fastened to hangers connected with the roof of the building. v

Within the recesses produced by the base sections l may be secured panels 29 so that the design or appearance of the hung ceiling will be the same as that produced by the apparatus of either Fig. 1 or Fig. '7.

The product of the mold form illustrated in Figs. 10 to 13, inclusive, is the same in design and appearance, when completed,v as that shown in Fig. 6.

The apparatus of Figs. 10 and 11 includes a single one-piece mold unit llc in the form of a sheet metal dome made at its bottom with an outstanding` flange 58a supported by the stringers 22. Mold units of this type are old inv this art.

In accordance with my invention I provide a plurality of intermediate groove-forming mold strips 35a and 36a alternating with the main mold units l Ic which they serve to hold in spaced apart relationship, said strips being seated upon the flanges 58' and provided upon their top sides with groove-forming ribsd.

The opposite side marginal portions of each strip 35a and 36a.' is made with an elevated countersink-forming step 59 whose opposite end portions are pointedly beveled at forty-five degrees so that abutting strips intermesh or match up to provide closed miterjoints as shown in Figs. 11, 12 and 13.

In this form of my invention the outer boarder strip 31a is constructed the same as the strips 31 of Figs. 1 to 9, inclusive, while the inner strip 38a is made at intervals throughout its length with an elevated countersink-forming stepped ilange 60, one opposite each proximate main unit llc. Each stepped flange 60 is bevele'd at its opposite ends to match up with the beveled ends of the two strips 36a which it abuts.

Notches or sockets 6I formed in the inner marginal portion of strip 38a between the flangesl) receive'the squared outer end portions 6|, Fig. 13, of the strips 36a.

What I claim is:

1. A ceiling mold form comprising a plurality of main mold units each consisting of two separable sections including a countersink-forming base section and an upper sectionmounted upon and separably associated therewith and a plurality of mold strips alternating and separably interlocked with said base sections so as to position each of the latter in spaced apart relationship, with respect to adjacent ybase sections. y 2. In a mold form of the character described, vthe combination of two mold units each made with a flange provided upon its top side with a longitudinal rib, and a mold strip element between said units made upon its under side with a pair of longitudinal grooves occupied by the ribs of the flanges of said mold units so thatthe latter are maintained in spaced apart relation-y ship by said strip.

3. In a mold formv of the character described,

the combination of two sheet metal mold kunits each made with a flange provided upon its top side with a longitudinal rib, and a sheet metal mold strip element between said units made upon its top side with two longitudinal grooveforming ribs and upon its under side with a pair of longitudinal grooves occupied bythe ribs of lthe iiang-es of said mold units so that the latter are maintained in spaced apart relationship by said strip. y

4. A ceiling mold form comprising a plurality of main cavity-forming mold units each made yunit and a plurality of mold strips surrounding and kseparably Iassociated with said unit, said strips being stepped upwardly immediately adjacent said unit, said upwardly stepped portions abutting the sides of said dome-like 'unit throughout the circuit thereof adjacent to but above the base of said unit so as to produce a relatively shallow panel-receiving countersink in the ceiling immediately surrounding the cavity produced by said unit.

PASQUALE CARILLI. 

